Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30600 -A30616) KOMATSU 730E – PDF DOWNLOAD
Original price was: $57.95.$26.95Current price is: $26.95.
- KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30600 -A30616
- PUBLICATION NUMBER:CEBM023301
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30600 -A30616) KOMATSU 730E
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30600 -A30616) KOMATSU 730E – PDF DOWNLOAD:
IMAGE PREVIEW:
DESCRIPTION:
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30600 -A30616) KOMATSU 730E
- This manual is written for use by the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions must be understood and followed when operating or repairing the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service, and reassembly. Each major serviceable component has a section in the shop manual. Disassembly of any component should only be done as far as necessary to accomplish needed repairs.
- The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning in metric units and in U.S. English units. All references to Right, Left, Front, or Rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements for common fasteners are shown in torque charts in the general information section.
- Special torque requirtements are provided in the text in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating.
- The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter E, when present, designates an electrical wheel motor drive system. The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW). GVW is total weight: the empty vehicle weight + the fuel and lubricants + the payload. To determine allowable payload, fill all lubricants and fuel tank to the proper level. Weigh the truck and record this value. Subtract it from the GVW to determine the allowable payload.
TABLE OF CONTENTS:
KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30600 -A30616) KOMATSU 730E
COVER...................................................................................................... 1 TABLE OF CONTENTS.......................................................................................... 7 SECTION A GENERAL INFORMATION INDEX........................................................................ 9 SECTION A2 MAJOR COMPONENTS AND SPECIFICATIONS......................................................... 13 Komatsu SSA16V159.................................................................................. 13 SECTION A3 GENERAL SAFETY AND OPERATION INDEX.......................................................... 15 GENERAL SAFETY AND OPERATION....................................................................... 18 PERSONAL SAFETY................................................................................ 18 Safety Rules............................................................................... 18 Truck Safety Features...................................................................... 18 Clothing And Personal Items................................................................ 18 Unauthorized Modification.................................................................. 18 Leaving The Operator’s Seat................................................................ 18 Mounting And Dismounting................................................................... 19 Fire Extinguishers And First Aid Kits...................................................... 19 Precautions For High Temperature Fluids.................................................... 19 Asbestos Dust Hazard Prevention............................................................ 20 Fire Prevention For Fuel And Oil........................................................... 20 ROPS Precautions........................................................................... 20 Preventing Injury From Work Equipment...................................................... 20 Precautions For Optional Attachments....................................................... 20 Precautions When Starting The Machine...................................................... 21 PRECAUTIONS FOR TRUCK OPERATION................................................................ 21 Safety Is Thinking Ahead................................................................... 21 Safety At The Work Site.................................................................... 21 Fire Prevention............................................................................ 21 Preparing For Operation.................................................................... 21 Ventilation For Enclosed Areas............................................................. 21 Mirrors, Windows, And Lights............................................................... 22 In The Operator’s Cab - Before Starting The Engine......................................... 22 Seat Belts................................................................................. 22 OPERATING THE MACHINE.......................................................................... 22 Starting The Engine........................................................................ 22 Truck Operation - General.................................................................. 23 Traveling In The Truck..................................................................... 23 Precautions When Traveling In Reverse...................................................... 23 Traveling On Slopes........................................................................ 24 Ensuring Good Visibility................................................................... 24 Operating On Snow.......................................................................... 24 Avoid Damage To The Dump Body.............................................................. 24 Driving Near High-Voltage Cables........................................................... 24 When Loading The Truck..................................................................... 24 When Dumping............................................................................... 24 Working On Loose Ground.................................................................... 25 Parking The Machine........................................................................ 25 TOWING......................................................................................... 25 WORKING NEAR BATTERIES......................................................................... 25 Battery Hazard Prevention.................................................................. 25 Jump-Starting With Booster Cables.......................................................... 26 Jump Starting With Receptacles............................................................. 26 PRECAUTIONS FOR MAINTENANCE........................................................................ 27 BEFORE PERFORMING MAINTENANCE.................................................................. 27 Stopping The Engine Before Service......................................................... 27 Warning Tag................................................................................ 27 Proper Tools............................................................................... 27 Securing The Dump Body..................................................................... 27 DURING MAINTENANCE............................................................................. 28 Personnel.................................................................................. 28 Attachments................................................................................ 28 Working Under The Machine.................................................................. 28 Keeping The Machine Clean.................................................................. 28 Rules To Follow When Adding Fuel Or Oil.................................................... 28 Radiator Coolant Level..................................................................... 28 Use Of Lighting............................................................................ 28 Precautions With The Battery............................................................... 29 Handling High-Pressure Hoses............................................................... 29 Precautions With High-Pressure Oil......................................................... 29 Maintenance Near High Temperatures And High Pressures...................................... 29 Rotating Fan And Belts..................................................................... 29 Waste Materials............................................................................ 29 TIRES.......................................................................................... 30 Handling Tires............................................................................. 30 Tire Maintenance........................................................................... 31 Storing Tires After Removal................................................................ 31 ADDITIONAL JOB SITE RULES.......................................................................... 32 WHEN REPAIRS ARE NECESSARY......................................................................... 33 OPERATING INSTRUCTIONS............................................................................. 34 PREPARING FOR OPERATION........................................................................ 34 SAFETY IS THINKING AHEAD....................................................................... 34 WALK AROUND INSPECTION......................................................................... 34 ENGINE START-UP................................................................................ 38 AFTER ENGINE HAS STARTED....................................................................... 39 EMERGENCY STEERING SYSTEM...................................................................... 40 Operation.................................................................................. 40 Pre-Operation Testing...................................................................... 40 Additional Guidelines...................................................................... 41 MACHINE OPERATION SAFETY PRECAUTIONS........................................................... 41 LOADING........................................................................................ 42 HAULING........................................................................................ 42 PASSING........................................................................................ 43 DUMPING........................................................................................ 43 To Raise The Dump Body:.................................................................... 43 To Lower The Dump Body: (When dumping over a berm or into a crusher):...................... 44 To Lower The Dump Body (When dumping on flat ground):...................................... 44 TOWING......................................................................................... 45 Towing Procedure........................................................................... 45 SAFE PARKING PROCEDURES........................................................................ 46 ENGINE SHUTDOWN PROCEDURE...................................................................... 46 DELAYED ENGINE SHUTDOWN PROCEDURE.............................................................. 46 SUDDEN LOSS OF POWER........................................................................... 47 TROLLEY OPERATING INSTRUCTIONS................................................................. 48 AFTER THE ENGINE HAS STARTED............................................................... 48 OPERATING IN DIESEL MODE................................................................... 48 OPERATING IN TROLLEY LINE MODE............................................................. 49 GETTING ON LINE............................................................................ 49 Operating On Trolley................................................................... 51 GETTING OFF LINE........................................................................... 52 LINE STATUS SIGNALS........................................................................ 52 LINE STATUS SIGNAL MARKINGS................................................................ 53 TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION........................................... 53 APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK............................... 54 OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS..................................... 54 TRUCK FAILURE WHILE ON TROLLEY............................................................. 54 SECTION A4 WARNINGS AND CAUTIONS....................................................................... 55 SECTION A5 TORQUE TABLES AND CONVERSION CHARTS......................................................... 65 SECTION A7 STORAGE AND IDLE MACHINE PREPARATION INDEX.................................................. 75 SHORT TERM IDLE PERIODS............................................................................ 77 PREPARATION FOR STORAGE............................................................................ 78 REMOVAL FROM STORAGE............................................................................... 79 RECONDITIONING AN IDLE VEHICLE..................................................................... 80 ENGINE OPERATION................................................................................... 83 After The Engine Has Started................................................................... 83 ENGINE STORAGE..................................................................................... 84 Temporary Storage (30 Days Or Less)............................................................ 84 Extended Storage (More Than 30 Days)........................................................... 85 RESTORING AN ENGINE AFTER EXTENDED STORAGE......................................................... 86 ELECTRIC DRIVE TRUCKS.............................................................................. 87 Storing A Truck That Is Operational............................................................ 87 Storing A Truck That Is Not Operational........................................................ 88 Storing A Major Component...................................................................... 89 Periodic Inspections........................................................................... 89 Placing Equipment Into Service After Storage................................................... 89 SECTION B STRUCTURES INDEX................................................................................. 91 SECTION B2 STRUCTURAL COMPONENTS INDEX................................................................. 93 STRUCTURAL COMPONENTS.............................................................................. 95 LADDERS........................................................................................ 95 Removal.................................................................................... 95 Installation............................................................................... 95 GRILLE AND HOOD................................................................................ 96 Removal.................................................................................... 96 Installation............................................................................... 96 RIGHT-HAND DECK................................................................................ 96 Removal.................................................................................... 96 Installation............................................................................... 98 CENTER DECK.................................................................................... 98 LEFT-HAND DECK................................................................................. 99 Removal.................................................................................... 99 Installation............................................................................... 99 SECTION B3 DUMP BODY INDEX............................................................................. 101 DUMP BODY.......................................................................................... 103 Removal........................................................................................ 103 Installation................................................................................... 104 BODY SLING......................................................................................... 104 BODY PADS.......................................................................................... 105 BODY GUIDE......................................................................................... 105 Adjustment..................................................................................... 105 BODY POSITION INDICATOR............................................................................ 106 HOIST LIMIT SWITCH................................................................................. 106 ROCK EJECTORS...................................................................................... 106 Inspection..................................................................................... 106 SECTION B4 FUEL TANK INDEX............................................................................. 107 FUEL TANK.......................................................................................... 109 Removal........................................................................................ 109 Repair......................................................................................... 109 Cleaning....................................................................................... 109 Installation................................................................................... 110 FUEL GAUGE SENDER.................................................................................. 111 Removal........................................................................................ 111 Installation................................................................................... 111 LOW FUEL SENDER.................................................................................... 112 Removal........................................................................................ 112 Installation................................................................................... 112 TANK BREATHER VALVE................................................................................ 113 Removal........................................................................................ 113 Installation................................................................................... 113 Disassembly.................................................................................... 113 Assembly....................................................................................... 113 FUEL RECEIVER (WIGGINS QUICK FILL)................................................................. 114 LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL)............................................ 115 SECTION C ENGINE INDEX .................................................................................... 117 SECTION C2 POWER MODULE INDEX.......................................................................... 119 POWER MODULE....................................................................................... 121 GENERAL INFORMATION............................................................................ 121 POWER MODULE SERVICE........................................................................... 122 Removal.................................................................................... 122 Installation............................................................................... 126 SECTION C3 COOLING SYSTEM INDEX........................................................................ 129 COOLING SYSTEM..................................................................................... 131 RADIATOR....................................................................................... 131 Removal.................................................................................... 131 Service.................................................................................... 132 Installation............................................................................... 132 RADIATOR FILL PROCEDURE........................................................................ 133 RADIATOR REPAIR................................................................................ 133 Internal Inspection........................................................................ 133 External Cleaning.......................................................................... 134 Disassembly................................................................................ 134 Cleaning and Inspection.................................................................... 135 Assembly................................................................................... 135 Additional Service Information............................................................. 137 PRESSURE TESTING............................................................................... 137 COOLANT SYSTEM TROUBLESHOOTING................................................................. 137 SECTION C4 POWER TRAIN INDEX........................................................................... 139 POWER TRAIN........................................................................................ 141 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE.................................................. 141 General Information........................................................................ 141 Removal.................................................................................... 141 ALTERNATOR INSTALLATION........................................................................ 143 Engine/Alternator Mating................................................................... 143 Alternator Measurement..................................................................... 143 Engine End Play Measurement................................................................ 144 Determining Shim Requirements.............................................................. 145 Installing Alternator On Engine............................................................ 146 ENGINE......................................................................................... 147 Removal.................................................................................... 147 Installation............................................................................... 147 SECTION C5 AIR CLEANERS INDEX.......................................................................... 149 OPERATION.......................................................................................... 151 SERVICING THE AIR CLEANERS......................................................................... 151 Replacing The Elements......................................................................... 152 AIR CLEANER ASSEMBLY CLEANING...................................................................... 153 Primary Element Cleaning....................................................................... 153 Precleaner Section Cleaning.................................................................... 155 AIR INTAKE TROUBLESHOOTING......................................................................... 156 SECTION C7 FAN DRIVE CLUTCH INDEX...................................................................... 157 COMPONENTS......................................................................................... 158 Input.......................................................................................... 158 Output......................................................................................... 158 Stationary Components.......................................................................... 159 OPERATIONAL MODES.................................................................................. 160 Fully Engaged.................................................................................. 160 Modulated Variable Speed....................................................................... 160 Fully Released................................................................................. 161 Lubricating and Cooling Oil.................................................................... 162 MAINTENANCE........................................................................................ 163 TROUBLESHOOTING.................................................................................... 164 Preliminary Checks............................................................................. 164 FIELD CHECK DIAGNOSIS.............................................................................. 165 Preliminary Checks - Engine Off................................................................ 165 Check Clutch Release........................................................................... 165 Check Clutch Lock-up........................................................................... 166 Overheating.................................................................................... 166 Thermal Sensor and Solenoid Valve.............................................................. 167 On Truck Test.................................................................................. 167 Off Truck Test................................................................................. 167 FAN CLUTCH DISASSEMBLY INSTRUCTIONS................................................................ 172 REASSEMBLY OF THE FAN CLUTCH....................................................................... 179 INSPECTION OF PARTS................................................................................ 190 REBUILD TOOLS...................................................................................... 194 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX................................................... 195 SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX.......................................................... 197 24VDC ELECTRIC SUPPLY SYSTEM....................................................................... 199 ELECTRICAL SYSTEM DESCRIPTION.................................................................. 199 BATTERIES...................................................................................... 199 Maintenance and Service.................................................................... 199 Troubleshooting............................................................................ 199 BATTERY CHARGING ALTERNATOR.................................................................... 201 24VDC ELECTRIC START SYSTEM........................................................................ 201 CRANKING MOTORS................................................................................ 201 Removal.................................................................................... 201 Installation............................................................................... 202 CRANKING MOTOR TROUBLESHOOTING................................................................. 202 Preliminary Inspection..................................................................... 203 No-Load Test............................................................................... 203 Interpreting Results of Tests.............................................................. 203 Disassembly................................................................................ 204 Cleaning and Inspection.................................................................... 204 Armature Servicing......................................................................... 205 Field Coil Checks.......................................................................... 207 Field Coil Removal......................................................................... 207 Solenoid Checks............................................................................ 207 Test....................................................................................... 207 Assembly................................................................................... 209 Pinion Clearance........................................................................... 210 MAGNETIC SWITCH................................................................................ 210 Coil Test.................................................................................. 210 Electric Start System Wiring Diagrams...................................................... 210 ENGINE PRELUB SYSTEM............................................................................... 211 OPERATION...................................................................................... 211 Pressure Switch............................................................................ 211 Suction Line............................................................................... 211 Outlet Line................................................................................ 211 Check Valve................................................................................ 211 Solenoid Timer............................................................................. 211 TROUBLESHOOTING PRELUB STARTER CIRCUIT............................................................. 213 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX.................................................... 217 24VDC ELECTRICAL SYSTEM COMPONENTS................................................................. 219 PASSENGER SEAT BASE COMPARTMENT................................................................ 219 COMPONENTS..................................................................................... 219 Taillight Resistor Diode Assemblies........................................................ 219 Inclinometer............................................................................... 219 Lubrication System Timer................................................................... 219 Three Minute Idle Timer Components......................................................... 219 Three Minute Idle Timer.................................................................... 221 Idle Timer Relay........................................................................... 221 Three Minute Idle Contactor................................................................ 221 Three Minute Idle Circuit Test............................................................. 221 Data Store Button.......................................................................... 221 Komatsu Engine Diagnostic Connector (Centry)............................................... 221 Komatsu Engine Diagnostic Port (CENSE)..................................................... 221 STATEX III Propulsion System Diagnostic Connector.......................................... 221 Modular Mining Port (Optional)............................................................. 221 Alarm Indicating Device (AID) System....................................................... 222 Diode Matrix (Without Sound)............................................................... 222 Diode Matrix (With Sound).................................................................. 223 Hot Switch Inverter........................................................................ 223 Hot Switch Inverter Card (Slot 4) (Not Used)............................................... 223 Temperature................................................................................ 223 Oil Level.................................................................................. 223 Temperature and Latch...................................................................... 223 Coolant Level/Flasher...................................................................... 224 Lamp Test.................................................................................. 224 BATTERY EQUALIZER BOX.......................................................................... 224 Troubleshooting............................................................................ 224 BODY POSITION SWITCHES......................................................................... 226 Proximity Switch Operation................................................................. 226 Body-Up Switch Adjustment.................................................................. 227 Hoist Limit Switch Adjustment.............................................................. 227 24-VOLT RELAY AND DIODE BOARDS................................................................. 229 RELAY BOARDS................................................................................... 230 Description................................................................................ 230 SERVICE........................................................................................ 230 To Replace A Relay:........................................................................ 230 To Replace A Circuit Breaker:.............................................................. 230 To Replace A Circuit Panel Card............................................................ 231 Relay Board Components..................................................................... 231 Installing Additional Circuits............................................................. 232 DIODE BOARD 1.............................................................................. 233 Diode Testing.............................................................................. 233 CIRCUIT BREAKERS............................................................................... 235 SECTION D10 CHARGING SYSTEM INDEX...................................................................... 237 CHARGING SYSTEM DESCRIPTION........................................................................ 239 PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION...................................................... 239 Excessive heat................................................................................. 239 Dirt and dust.................................................................................. 239 Vibration...................................................................................... 239 PREVENTIVE MAINTENANCE PROCEDURES.................................................................. 240 Alternator Cleanliness......................................................................... 240 Alternator Mounting............................................................................ 240 Belt Tension And Condition..................................................................... 240 TROUBLESHOOTING PROCEDURES......................................................................... 240 ALTERNATOR PERFORMANCE TEST........................................................................ 240 ALTERNATOR PERFORMANCE TEST - LOAD APPLIED......................................................... 241 ALTERNATOR CABLE TEST.............................................................................. 241 VOLTAGE REGULATOR ADJUSTMENT....................................................................... 242 ALTERNATOR......................................................................................... 243 Removal........................................................................................ 243 Installation................................................................................... 244 SECTION D35 PAYLOAD METER III INDEX.................................................................... 247 OPERATION SECTION.................................................................................. 251 Introduction................................................................................... 251 Data Summary............................................................................... 251 Data Gathering............................................................................. 251 COMPONENT DESCRIPTION.......................................................................... 252 System Diagram............................................................................. 252 Suspension Pressure Sensors................................................................ 252 Inclinometer............................................................................... 252 Operator Display........................................................................... 252 Operator Switch............................................................................ 253 Speed Input................................................................................ 253 Body-Up Switch............................................................................. 253 Brake Lock Switch.......................................................................... 253 Payload Meter.............................................................................. 253 Communications Ports....................................................................... 253 Key Switch Input........................................................................... 254 Payload Meter Power........................................................................ 254 Load Lights................................................................................ 254 Wiring and Termination..................................................................... 255 TCI Outputs................................................................................ 255 OPERATOR’S DISPLAY AND SWITCH.................................................................. 256 Reading the Speedometer.................................................................... 256 Reading the Load Display................................................................... 256 Using the Operator ID...................................................................... 256 Using the Load and Ton Counter............................................................. 256 Total Ton Counter.......................................................................... 256 Total Load Counter......................................................................... 257 Clearing the Counters...................................................................... 257 Viewing Live Sensor Data................................................................... 257 Other Display Messages..................................................................... 257 PAYLOAD OPERATION & CALCULATION................................................................ 258 Description of Haul Cycle States........................................................... 258 Haul Cycle Description..................................................................... 258 Load Calculation........................................................................... 259 Carry Back................................................................................. 259 Measurement Accuracy....................................................................... 259 SOURCES FOR PAYLOAD ERROR...................................................................... 259 Payload Error.............................................................................. 259 Loading Conditions......................................................................... 260 Pressure Sensors........................................................................... 260 Swingloads................................................................................. 260 Speed and Distance......................................................................... 260 HAUL CYCLE DATA................................................................................ 260 Haul Cycle Warning Flags................................................................... 262 Frame Torque Data.......................................................................... 263 Sprung Weight Data......................................................................... 263 Maximum Speed Data......................................................................... 263 Alarm Records.............................................................................. 263 Fault Code Data............................................................................ 264 PC SOFTWARE OVERVIEW........................................................................... 265 System Configuration....................................................................... 265 Installing the PLMIII Software............................................................. 265 DOWNLOADING DATA............................................................................... 266 PLM III SYSTEM CONFIGURATION................................................................... 267 Starting Communications.................................................................... 267 Displayed Payload Units.................................................................... 267 Time Units................................................................................. 267 Connection Menu............................................................................ 267 Connecting to the Payload Meter............................................................ 268 Configure the Payload Meter................................................................ 268 Setting the Date and Time.................................................................. 268 Setting the Truck Type..................................................................... 269 Setting the Gauge Display Units............................................................ 269 Setting the Frame Serial Number............................................................ 269 Setting the Truck Number................................................................... 269 Setting the Komatsu Distributor............................................................ 269 Setting the Komatsu Customer............................................................... 269 Clean Truck Tare........................................................................... 270 Inclinometer Calibration................................................................... 270 DATA ANALYSIS.................................................................................. 271 Creating a Query........................................................................... 271 Sorting on Truck Unit Number............................................................... 271 Sorting on Truck Type...................................................................... 271 Sorting on Date Range...................................................................... 272 Sorting on Time Range...................................................................... 272 Payload Detail Screen...................................................................... 273 Creating Reports........................................................................... 273 Summary - one page report.................................................................. 274 Detailed - multi-page report............................................................... 274 Creating Graphs............................................................................ 275 Exporting Data............................................................................. 275 CSV Export................................................................................. 275 Compressed................................................................................. 276 Importing Data............................................................................. 277 Deleting Haul Cycle Records................................................................ 277 Viewing Alarms............................................................................. 278 Deleting Alarm Records..................................................................... 278 TROUBLESHOOTING SECTION............................................................................ 279 TROUBLESHOOTING................................................................................ 279 Viewing Active Alarms...................................................................... 279 Real-Time Data Display..................................................................... 279 Testing the Payload Lights................................................................. 279 Creating Log Files of Inputs............................................................... 280 Daily Inspections.......................................................................... 280 Periodic Maintenance....................................................................... 280 Abnormal Displays at Power-Up.............................................................. 281 No Payload Display When Key Switch is Turned ON............................................ 282 No Display on Speedometer.................................................................. 283 No Display on Operator Display............................................................. 283 No Communications With PC.................................................................. 284 Load Lights Don’t Light During Loading..................................................... 285 Load Lights Remain ON...................................................................... 286 Load Lights Remain ON During Dumping....................................................... 286 Display Doesn't Clear When The Load Is Dumped.............................................. 286 Calibration Problems....................................................................... 287 Alarm 1 - Left Front Pressure High......................................................... 288 Alarm 2 - Left Front Pressure Low.......................................................... 288 Troubleshoot Wiring to Left Front Suspension............................................... 288 Alarm 3 - Right Front Pressure High........................................................ 289 Alarm 4 - Right Front Pressure Low......................................................... 289 Troubleshoot Wiring to Right Front Suspension.............................................. 289 Alarm 5 -Left Rear Pressure High........................................................... 290 Alarm 6 - Left Rear Pressure Low........................................................... 290 Troubleshoot Wiring to Left Rear Suspension................................................ 290 Alarm 7 - Right Rear Pressure High......................................................... 291 Alarm 8 - Right Rear Pressure Low.......................................................... 291 Troubleshoot Wiring to Right Rear Suspension............................................... 291 Alarm 9 - Inclinometer High................................................................ 292 Alarm 10 - Inclinometer Low................................................................ 292 Troubleshoot Inclinometer Wiring........................................................... 292 Alarm 13 - Body Up Input Failure........................................................... 293 Alarm 16 - Memory Write Failure............................................................ 294 Alarm 17 - Memory Read Failure............................................................. 294 Alarm 18................................................................................... 295 Alarm 19................................................................................... 295 Alarm 22................................................................................... 295 Operator Switch Doesn't Work............................................................... 296 Alarm 26 - User Switch Fault - SELECT...................................................... 296 Alarm 27 - User Switch Fault - SET......................................................... 296 Connector Map.............................................................................. 297 Connectors................................................................................. 298 PLMIII CHECK OUT PROCEDURE......................................................................... 299 General Description............................................................................ 299 Tools Required................................................................................. 299 Checkout Procedure............................................................................. 299 PLMIII CHECKOUT PROCEDURE CONFIRMATION......................................................... 303 Flashburn Programming...................................................................... 303 Confirmation Checklist..................................................................... 305 SECTION E ELECTRICAL PROPULSION INDEX...................................................................... 307 SECTION E2 ELECTRICAL PROPULSION COMPONENTS INDEX...................................................... 309 GENERAL SYSTEM DESCRIPTION......................................................................... 313 CONTROL SYSTEM..................................................................................... 313 System Operation............................................................................... 314 FL275 Panel.................................................................................... 315 CARD REPLACEMENT................................................................................... 316 Removal........................................................................................ 316 Installation................................................................................... 316 Card Repair.................................................................................... 316 Panel Wiring................................................................................... 316 COMPUTER DESCRIPTION............................................................................... 317 Microprocessor................................................................................. 317 Download Capability............................................................................ 317 SOFTWARE........................................................................................... 317 Base Monitor Program........................................................................... 317 Runtime Monitor Program - OBJ Running Code..................................................... 317 Configuration Software - CFG................................................................... 318 PTU - Portable Test Unit Code.................................................................. 318 System Regulation.............................................................................. 318 Propulsion..................................................................................... 319 Retarding...................................................................................... 319 TWO-DIGIT DISPLAY PANEL............................................................................ 320 The Coded Number............................................................................... 320 Events......................................................................................... 320 Frames......................................................................................... 321 Windows........................................................................................ 321 System Categories.............................................................................. 321 Limits On Resetting Faults..................................................................... 321 NA Faults...................................................................................... 322 Event Sequence................................................................................. 322 Resetting Events............................................................................... 322 Event Descriptions............................................................................. 322 Subcode Descriptions........................................................................... 322 2-DIGIT DISPLAY PANEL SUBCODES..................................................................... 330 PORTABLE TEST UNIT (PTU)........................................................................... 333 DESCRIPTION.................................................................................... 333 Operational Hints.......................................................................... 333 SOFTWARE INSTALLATION PREPARATION.............................................................. 334 HARD DISK SPACE REQUIREMENTS................................................................... 334 SOFTWARE INSTALLATION ON PTU................................................................... 334 PTU/Truck Communication Problems........................................................... 335 THE MAIN MENU.................................................................................. 336 Quit Menu.................................................................................. 336 PTU Talk To Truck.......................................................................... 336 View PTU Saved Files....................................................................... 336 List Stat Data Files....................................................................... 336 Truck Setup (CFG).......................................................................... 336 Select Truck Setup......................................................................... 336 Update CFG Version......................................................................... 336 Change PTU Password........................................................................ 336 CONFIGURATION (CFG) FILE CONVERSION............................................................ 338 Conversion Procedure....................................................................... 338 Convert Old CFG files for New software..................................................... 339 STATEX CONFIGURATION FILES..................................................................... 342 0) Source Directory: . . .................................................................. 342 1) Select A Truck Configuration . . ....................................................... 343 2) View Truck Configuration: Data Curves . . .............................................. 344 3) Change/View Serial and Model Numbers . . ............................................... 345 4) View Options . . ....................................................................... 345 5) Change/View Truck Specifics . . ........................................................ 347 6) Change/View Overspeeds . . ............................................................. 349 7) Save a Truck Configuration, filename: . . .............................................. 350 8) Save Directory: . . .................................................................... 351 CHANGE PTU PASSWORD............................................................................ 352 PROGRAMMING THE TRUCK.......................................................................... 353 Connect PTU to the Truck................................................................... 353 Select Configuration File.................................................................. 353 Activate The PTU Mode...................................................................... 353 Check Object Code Version.................................................................. 354 Download Configuration Files............................................................... 355 Date And Time.............................................................................. 356 Event Data................................................................................. 357 Statistical Data........................................................................... 359 View Counters.............................................................................. 359 View Profiles.............................................................................. 359 Upload Statistical Data To A File.......................................................... 359 Statistical Data Codes - Counters.......................................................... 360 STATISTICAL DATA CODES - COUNTERS.............................................................. 361 STATISTICAL DATA CODES - PROFILES.............................................................. 366 TRUCK SPECIFIC INFORMATION..................................................................... 370 Temporary Truck Settings................................................................... 371 MISCELLANEOUS FEATURES......................................................................... 372 Saving Data................................................................................ 372 PTU Abbreviations.......................................................................... 373 Other Menu Selections...................................................................... 373 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..................................................... 374 ALTERNATOR..................................................................................... 374 ELECTRIC WHEEL MOTORS.......................................................................... 374 RETARDING GRIDS................................................................................ 374 ELECTRONIC ACCELERATOR AND RETARD PEDALS....................................................... 374 Removal.................................................................................... 374 Installation............................................................................... 374 Disassembly................................................................................ 375 Reassembly................................................................................. 375 COOLING BLOWER WARNING SYSTEM.................................................................. 375 Operation.................................................................................. 375 Test....................................................................................... 375 Removal.................................................................................... 376 Installation............................................................................... 376 ELECTRICAL CONTROL CABINET......................................................................... 377 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS............................................. 382 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III................................................. 383 SECTION E3 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE INDEX....................................... 385 GENERAL INFORMATION................................................................................ 389 COMMUNICATIONS PORT CHECK.......................................................................... 390 PTU Hookup..................................................................................... 390 4.0 SEQUENCE TESTS - (ENGINE NOT ON)............................................................... 391 Preparation and Setup.......................................................................... 391 CONTROL SYSTEM SELF-TEST....................................................................... 392 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT....................................................... 392 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT......................................................... 393 PTU Setup.................................................................................. 393 4.3 REVERSER AND PROPULSION CONTACTORS CHECK................................................... 394 4.4 NOT USED................................................................................... 395 4.5 RETARD CONTACTORS OPERATION CHECK.......................................................... 395 4.6 GROUND FAULT SENSING CHECK................................................................. 395 4.7 GROUND FAULT IN RETARD OPERATION CHECK..................................................... 396 4.8 OVERRIDE OPERATION CHECK................................................................... 396 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK.......................................................... 397 4.10 OVERSPEED RETARD OPERATION CHECK.......................................................... 397 4.11 HOIST INTERLOCK OPERATION CHECK........................................................... 398 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK.................................................. 398 Return to Main Menu........................................................................ 398 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL........................................... 399 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU.............................................. 399 5.2 DIGITAL INPUT CHECKS....................................................................... 400 5.3 DIGITAL OUTPUT CHECKS...................................................................... 401 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL................................................... 405 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU................................................... 405 6.2 ANALOG INPUT CHECKS........................................................................ 406 6.3 FREQUENCY INPUT CHECKS..................................................................... 410 Return to Main Menu........................................................................ 411 7.0 SPEED EVENT CHECKS............................................................................. 411 Preparation and Setup.......................................................................... 411 Setup PTU...................................................................................... 411 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK.................................... 412 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK......................... 412 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK........................ 412 7.4 OTHER SPEED EVENTS CHECKS.................................................................. 412 Return to Main Menu........................................................................ 412 8.0 RETARD SPEED CONTROL SYSTEM CHECK.............................................................. 413 Preparation and Setup.......................................................................... 413 Setup PTU...................................................................................... 413 8.1 OVERSPEED PICKUP AND DROPOUT CHECK......................................................... 413 8.2 RETARD POT MAXIMUM SETTING CHECK........................................................... 413 8.3 RETARD POT MINIMUM SETTING CHECK........................................................... 413 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL......................................... 414 Return to Main Menu........................................................................ 414 9.0 LOAD TEST USING TRUCK RETARD GRIDS............................................................. 414 Setup and Preparation.......................................................................... 414 PTU Setup...................................................................................... 414 9.1 LOAD TEST.................................................................................. 415 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING........................................................ 415 Setup PTU...................................................................................... 415 10.1 RETARD CHECK.............................................................................. 416 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT................................................... 417 11.1 BRAKE SYSTEM INTERLOCKS CHECK............................................................. 417 Preparation................................................................................ 417 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT.................................................... 417 11.3 SYNC TRANSFORMER CHECKOUT................................................................. 418 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT................................................ 418 11.5 BATTERY BOOST ADJUSTMENT.................................................................. 418 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST............................................... 418 11.7 MOTOR ROTATION TEST....................................................................... 419 11.8 GROUND FAULT CHECKS....................................................................... 419 12.0 MISCELLANEOUS CHARTS.......................................................................... 420 12.1 WHEEL MOTOR GEAR RATIOS................................................................... 420 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS............................................................ 421 12.3 ENGINE.................................................................................... 422 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS INDEX............................................................ 423 SECTION G2 TIRES AND RIMS INDEX........................................................................ 425 GENERAL INFORMATION................................................................................ 427 TIRES.............................................................................................. 427 Handling Tires................................................................................. 427 Tire Maintenance............................................................................... 428 Storing Tires After Removal.................................................................... 428 FRONT TIRES AND RIMS............................................................................... 429 Removal........................................................................................ 429 Installation................................................................................... 430 REAR TIRES AND RIMS................................................................................ 431 Removal........................................................................................ 431 Installation................................................................................... 432 RIM............................................................................................ 433 Tire Removal................................................................................... 433 RIM AND TIRE PREPARATION........................................................................... 434 LUBRICANTS......................................................................................... 434 TIRE INSTALLATION.................................................................................. 435 SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX........................................................... 437 FRONT WHEEL HUB AND SPINDLE........................................................................ 439 WHEEL HUB AND SPINDLE ASSEMBLY................................................................. 439 Removal.................................................................................... 439 Installation............................................................................... 441 Disassembly................................................................................ 442 Cleaning and Inspection.................................................................... 443 Assembly................................................................................... 443 Wheel Bearing Adjustment (Spindle Vertical)................................................ 446 Wheel Bearing Adjustment (Tire Mounted).................................................... 447 STEERING CYLINDERS AND TIE ROD................................................................. 451 Spherical Bearing Wear Limits.............................................................. 451 Removal.................................................................................... 452 Installation............................................................................... 454 Bearing Replacement........................................................................ 454 TOE-IN ADJUSTMENT.............................................................................. 455 SECTION G4 REAR AXLE HOUSING ATTACHMENTS INDEX......................................................... 457 REAR AXLE HOUSING.................................................................................. 467 REAR AXLE HOUSING.............................................................................. 467 Removal.................................................................................... 467 Installation............................................................................... 467 WHEEL MOTOR.................................................................................... 468 Removal.................................................................................... 468 Cleaning and Inspection.................................................................... 468 Installation............................................................................... 469 WHEEL MOTOR GEAR OIL........................................................................... 472 Change/Filter The Gear case Oil............................................................ 472 Oil........................................................................................ 472 Remove And Clean Magnetic Plugs............................................................ 472 Flushing The Gearbox....................................................................... 472 Check Gear Case Oil Level.................................................................. 472 PIVOT PIN.......................................................................................... 459 Removal........................................................................................ 459 Installation................................................................................... 460 PIVOT EYE BEARING.................................................................................. 460 Disassembly.................................................................................... 460 Assembly....................................................................................... 461 PIVOT EYE REPAIR................................................................................... 461 Removal........................................................................................ 461 Disassembly.................................................................................... 461 Bushing (New).................................................................................. 461 Pivot Eye Bore (New)........................................................................... 461 Assembly....................................................................................... 461 Installation................................................................................... 462 ANTI-SWAY BAR...................................................................................... 462 Removal........................................................................................ 462 Installation................................................................................... 462 Disassembly.................................................................................... 463 Cleaning and Inspection........................................................................ 463 Assembly....................................................................................... 463 SECTION G5 REAR AXLE HOUSING........................................................................... 465 REAR AXLE HOUSING.................................................................................. 467 SECTION H SUSPENSIONS INDEX................................................................................ 473 SECTION H2 FRONT SUSPENSION INDEX...................................................................... 475 Removal............................................................................................ 477 Installation....................................................................................... 479 Angle Advance Tightening Procedure................................................................. 480 Disassembly........................................................................................ 481 Cleaning and Inspection............................................................................ 482 Assembly (Bearing Only)............................................................................ 482 Suspension Assembly (Complete)..................................................................... 482 SUSPENSION PRESSURE TEST........................................................................... 484 SECTION H3 REAR SUSPENSIONS INDEX...................................................................... 487 Removal............................................................................................ 490 Installation....................................................................................... 492 Disassembly........................................................................................ 492 Cleaning and Inspection............................................................................ 493 Assembly........................................................................................... 493 SUSPENSION PRESSURE TEST........................................................................... 495 SECTION H4 OILING AND CHARGING PROCEDURES INDEX........................................................ 497 GENERAL............................................................................................ 499 EQUIPMENT LIST..................................................................................... 499 Hydrair® Charging Kit.......................................................................... 499 Installation of Charging Kit................................................................... 499 Removal of Charging Kit........................................................................ 500 Support Blocks For Oiling and Charging Dimensions.............................................. 500 FRONT SUSPENSION................................................................................... 501 Front Suspension Oiling........................................................................ 501 Front Suspension Nitrogen Charging............................................................. 502 REAR SUSPENSION.................................................................................... 504 Rear Suspension Oiling......................................................................... 504 Rear Suspension Nitrogen Charging.............................................................. 506 SECTION J BRAKE CIRCUIT INDEX.............................................................................. 509 SECTION J2 BRAKE CIRCUIT INDEX......................................................................... 511 GENERAL DESCRIPTION................................................................................ 513 SERVICE BRAKE CIRCUIT.............................................................................. 513 SECONDARY BRAKING AND AUTOMATIC APPLY.............................................................. 515 PARKING BRAKE CIRCUIT.............................................................................. 515 Normal Operation (key switch on, engine on).................................................... 515 BRAKE LOCK CIRCUIT................................................................................. 516 WARNING CIRCUIT.................................................................................... 516 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX....................................................... 519 BRAKE CIRCUIT COMPONENT SERVICE.................................................................... 521 BRAKE VALVE.................................................................................... 521 Rebuild Criteria........................................................................... 521 Removal.................................................................................... 521 Installation............................................................................... 523 Disassembly................................................................................ 525 Cleaning and Inspection.................................................................... 527 ASSEMBLY....................................................................................... 527 Actuator Base Threaded Inserts............................................................. 527 Boot and Cap............................................................................... 527 Valve Body Seal Installation............................................................... 528 Regulator Sleeve O-Ring Installation....................................................... 529 Actuator Plunger O-Ring Installation....................................................... 529 Assembly of Valve.......................................................................... 529 DIFFERENTIAL PRESSURE SWITCH................................................................... 530 Disassembly................................................................................ 531 Cleaning and Inspection.................................................................... 531 Assembly................................................................................... 531 VALVE BENCH TEST AND ADJUSTMENT................................................................ 531 Test Set Up Procedure...................................................................... 533 Brake Valve Output Pressure Adjustment..................................................... 533 Differential Pressure Switch Test.......................................................... 534 Final Test and Adjustment.................................................................. 534 Installation Of Brake Pedal Actuator Assembly to Brake Valve............................... 535 HYDRAULIC BRAKE ACCUMULATORS................................................................... 537 Brake Accumulator Bleed-Down Procedure..................................................... 537 Removal.................................................................................... 537 Installation............................................................................... 539 Disassembly................................................................................ 539 Cleaning and Inspection.................................................................... 541 Assembly................................................................................... 541 Leak Testing............................................................................... 544 BRAKE ACCUMULATOR CHARGING..................................................................... 545 Temperature During Precharge............................................................... 547 ACCUMULATOR STORAGE............................................................................ 547 Installation............................................................................... 548 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX..................................................... 549 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................................. 551 EQUIPMENT REQUIRED............................................................................. 554 INITIAL SYSTEM SET-UP.......................................................................... 555 Parking Brake.............................................................................. 555 Service Brakes............................................................................. 556 Brake Lock/Secondary....................................................................... 556 Low Brake Pressure and Auto Apply.......................................................... 557 Reapplications............................................................................. 557 Differential Pressure Switch............................................................... 557 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...................................................... 559 The Brakes are Locked, Service, and/or Parking................................................. 559 Both Brake Circuits are Dragging............................................................... 559 One Brake Circuit is Dragging.................................................................. 559 Brakes are Not Going to Full Pressure.......................................................... 559 A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off......................... 559 Differential Pressure Warning Circuit Activates Briefly When Brakes are Applied or Released.... 560 Differential Pressure Warning Circuit is Not Operating......................................... 560 A Low Brake Pressure Warning Occurs When Brakes are Applied.................................... 560 Low Pressure Warning Circuit Not Operating Properly............................................ 560 Low Pressure Warning is On Even Though System Pressure is Correct.............................. 561 Low Pressure Warning Comes On and Pressure is Low.............................................. 561 A Squeal is Heard When Controller is Operated.................................................. 561 Output Pressure At Controller is Correct but Brakes are Not Applying........................... 561 Brake Pressures Drift Excessively While Pedal is Held Steady................................... 561 Oil is Leaking Around the Pedal Base........................................................... 561 Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM....................... 561 CHECK-OUT PROCEDURE................................................................................ 562 HYDRAULIC BRAKE SYSTEM DATA SHEET.................................................................. 562 SECTION J5 FRONT DISC BRAKES INDEX..................................................................... 565 BRAKE CALIPER...................................................................................... 567 Removal........................................................................................ 567 Installation................................................................................... 568 Disassembly.................................................................................... 569 Cleaning and Inspection........................................................................ 569 Assembly....................................................................................... 571 BRAKE LINING....................................................................................... 571 Replacement.................................................................................... 571 FRONT SERVICE BRAKE BURNISHING..................................................................... 573 BRAKE BLEEDING PROCEDURE....................................................................... 574 REAR DISC BRAKES................................................................................... 577 REAR BRAKES.................................................................................... 577 CALIPER, DISC, AND PARKING BRAKE............................................................... 577 Removal.................................................................................... 577 Installation............................................................................... 578 CALIPER PISTON................................................................................. 580 Piston Assembly Removal.................................................................... 580 Inspection................................................................................. 580 Piston Assembly Installation............................................................... 581 FUNCTIONAL TEST OF PISTON ASSEMBLY............................................................. 582 Return Spring Force........................................................................ 582 Built-In Clearance......................................................................... 582 Grip Force................................................................................. 584 Grip Force Measurement..................................................................... 585 Spring Force Measurement................................................................... 587 Disassembly of Piston Assembly............................................................. 588 Assembly of Piston Assembly................................................................ 589 BENCH TEST..................................................................................... 589 BRAKE LINING................................................................................... 590 Replacement................................................................................ 590 SERVICE BRAKE BURNISHING........................................................................... 593 SAFETY PRECAUTIONS............................................................................. 593 Rear Brake Burnishing...................................................................... 594 BRAKE BLEEDING PROCEDURE....................................................................... 595 Spring Force Measurement................................................................... 596 SECTION J6 REAR BRAKES INDEX........................................................................... 575 REAR DISC BRAKES................................................................................... 577 SECTION J7 PARKING BRAKE INDEX......................................................................... 597 GENERAL INFORMATION................................................................................ 599 PARKING BRAKE CALIPER.............................................................................. 599 Lining Thickness Inspection.................................................................... 599 Removal........................................................................................ 600 Installation................................................................................... 600 Parking Brake Adjustment....................................................................... 601 Parking Brake Caliper Disassembly.............................................................. 602 Cleaning and Inspection........................................................................ 603 Parking Brake Caliper Assembly................................................................. 604 PARKING BRAKE LINING REPLACEMENT................................................................... 604 PARKING BRAKE BURNISH PROCEDURE.................................................................... 604 Lining Conditioning............................................................................ 604 BRAKE BLEEDING PROCEDURE........................................................................... 605 SECTION L HYDRAULIC SYSTEM INDEX........................................................................... 607 SECTION L2 HYDRAULIC SYSTEM OVERVIEW.................................................................. 609 HYDRAULIC SYSTEM OVERVIEW.......................................................................... 610 Hoist Circuit Operation........................................................................ 610 Steering, Brake and Pantograph Circuit Operation............................................... 610 Axle Blower System Operation................................................................... 610 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX..................................................... 613 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................................. 615 HOIST PUMP..................................................................................... 615 Removal.................................................................................... 615 Installation............................................................................... 617 Disassembly................................................................................ 617 Inspection................................................................................. 620 Assembly................................................................................... 621 PISTON PUMP................................................................................ 626 Removal................................................................................ 626 Installation........................................................................... 627 Disassembly............................................................................ 629 Inspection of Parts.................................................................... 635 Assembly............................................................................... 637 AXLE BLOWER HYDRAULIC MOTOR........................................................................ 642 Removal........................................................................................ 642 Installation................................................................................... 642 Rear Axle Blower Housing....................................................................... 642 Disassembly................................................................................ 642 Assembly................................................................................... 643 Disassembly................................................................................ 645 Inspection................................................................................. 647 Assembly................................................................................... 648 Trouble Shooting........................................................................... 649 Hand Wheel Control............................................................................. 650 Disassembly................................................................................ 650 Assembly................................................................................... 650 HYDRAULIC TANK................................................................................. 652 Filling Instructions....................................................................... 652 Removal.................................................................................... 653 Installation............................................................................... 653 HYDRAULIC TANK STRAINER AND DIFFUSER........................................................... 654 Removal.................................................................................... 654 Inspect and Clean.......................................................................... 655 Installation............................................................................... 655 SECTION L4 STEERING CIRCUIT INDEX...................................................................... 657 STEERING CIRCUIT OPERATION......................................................................... 659 COMPONENT DESCRIPTION.............................................................................. 660 Steering Control Valve......................................................................... 660 Unloader Valve................................................................................. 661 Bleed-Down Manifold Valve...................................................................... 661 Flow Amplifier................................................................................. 666 FLOW AMPLIFIER SYSTEM OPERATION.................................................................... 667 No Steer....................................................................................... 667 Steering Left.................................................................................. 669 Steering Right................................................................................. 671 No Steer, External Shock Load.................................................................. 673 Steering Pump.................................................................................. 675 High Pressure Filter........................................................................... 675 Accumulators................................................................................... 675 Low Precharge Warning Switch................................................................... 675 SECTION L5 STEERING CONTROL VALVE INDEX................................................................ 677 Removal............................................................................................ 679 Installation....................................................................................... 680 STEERING CONTROL VALVE REBUILD..................................................................... 681 Disassembly.................................................................................... 681 Cleaning and Inspection........................................................................ 682 Assembly....................................................................................... 682 BRAKE / STEERING PUMP.............................................................................. 686 Removal........................................................................................ 686 Installation................................................................................... 688 Disassembly.................................................................................... 689 Inspection of Parts............................................................................ 689 Assembly....................................................................................... 691 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX..................................................... 693 STEERING CIRCUIT COMPONENT REPAIR.................................................................. 695 BLEED-DOWN MANIFOLD............................................................................ 695 Removal.................................................................................... 695 Installation............................................................................... 695 ACCUMULATOR.................................................................................... 696 Removal.................................................................................... 696 Installation............................................................................... 697 Disassembly................................................................................ 698 Cleaning and Inspection.................................................................... 698 Assembly................................................................................... 699 Leak Testing............................................................................... 700 STEERING ACCUMULATOR CHARGING.................................................................. 701 Temperature During Precharge............................................................... 704 ACCUMULATOR STORAGE............................................................................ 705 Installation............................................................................... 705 FLOW AMPLIFIER................................................................................. 706 Removal.................................................................................... 706 Installation............................................................................... 706 Disassembly................................................................................ 707 Assembly................................................................................... 710 STEERING CYLINDERS............................................................................. 711 Disassembly................................................................................ 711 Piston Seal and Bearing Installation....................................................... 711 Cylinder Assembly.......................................................................... 711 Test....................................................................................... 711 TROUBLESHOOTING CHART.............................................................................. 714 SECTION L7 HOIST CIRCUIT INDEX......................................................................... 719 HOIST CIRCUIT OPERATION............................................................................ 721 COMPONENT DESCRIPTION.............................................................................. 722 Hydraulic Tank................................................................................. 722 Hydraulic Pump................................................................................. 722 High Pressure Filter........................................................................... 722 Hoist Valve.................................................................................... 722 Hoist Pilot Valve.............................................................................. 723 Bleed-Down Manifold............................................................................ 724 Counterbalance Manifold........................................................................ 724 Hoist-Up Limit Solenoid........................................................................ 724 Pilot Operated Check Valve..................................................................... 724 HOIST VALVE OPERATION.............................................................................. 726 Float Operation................................................................................ 726 Power Up Operation (Figure 7-6)................................................................ 728 Hold Operation (Figure 7-7).................................................................... 730 Power Down Operation (Figure 7-8).............................................................. 732 Float Operation (Figure 7-9)................................................................... 734 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX........................................................ 737 HOIST VALVE........................................................................................ 739 Removal........................................................................................ 739 Installation................................................................................... 739 O-Ring Replacement............................................................................. 741 INLET SECTION...................................................................................... 742 Disassembly.................................................................................... 742 Cleaning and Inspection........................................................................ 743 Assembly....................................................................................... 743 REAR SPOOL SECTION (WORK PORTS).................................................................... 744 Disassembly.................................................................................... 744 Cleaning and Inspection........................................................................ 746 Assembly....................................................................................... 746 HOIST PILOT VALVE.................................................................................. 748 Removal........................................................................................ 748 Installation................................................................................... 748 Disassembly.................................................................................... 749 Cleaning and Inspection........................................................................ 750 Assembly....................................................................................... 750 HOIST UP LIMIT SOLENOID VALVE...................................................................... 751 HOIST CYLINDERS.................................................................................... 752 Removal........................................................................................ 752 Installation................................................................................... 753 Disassembly.................................................................................... 755 Cleaning and Inspection........................................................................ 756 SS1143 Tightening Tool - Assembly Drawing...................................................... 757 ASSEMBLY OF QUILL AND CYLINDER..................................................................... 757 Quill Installation............................................................................. 757 Installation Of Check Balls And Plugs In Quill................................................. 758 Assembly of Cylinder........................................................................... 760 Pressure Testing............................................................................... 761 COUNTERBALANCE MANIFOLD............................................................................ 761 SECTION L9 HIGH PRESSURE FILTERS INDEX................................................................. 763 HOIST CIRCUIT FILTER............................................................................... 765 Filter Element Replacement..................................................................... 765 Removal........................................................................................ 766 Installation................................................................................... 766 Indicator Switch............................................................................... 766 STEERING CIRCUIT FILTER............................................................................ 767 Filter Element Replacement..................................................................... 767 Removal........................................................................................ 768 Installation................................................................................... 768 Indicator Switch............................................................................... 768 INDICATOR SWITCH................................................................................... 768 Test Procedure................................................................................. 768 SECTION L10 HYDRAULIC CHECK-OUT PROCEDURE INDEX........................................................ 771 INITIAL START UP AND FLUSHING...................................................................... 773 COMPONENT CHECKOUT AND ADJUSTMENT.................................................................. 775 ADJUSTMENT PROCEDURE FOR HOIST COUNTERBALANCE CARTRIDGE VALVE...................................... 777 Counterbalance Valve Adjustment................................................................ 779 Manifold Assembly.............................................................................. 779 OIL CLEANLINESS CHECK.............................................................................. 779 Oil Sampling Location On Truck................................................................. 779 Oil Sampling Process and Cleanliness Criteria.................................................. 780 DISABLED TRUCK DUMPING PROCEDURE................................................................... 780 Hookup......................................................................................... 780 Raising the Body............................................................................... 780 Lowering the Body.............................................................................. 781 TROUBLESHOOTING CHART.............................................................................. 782 Hoist Pump..................................................................................... 782 Steering Circuit............................................................................... 784 Brake/Steering Pump............................................................................ 786 Flow Amplifier - Refer to Figure 10-9.......................................................... 788 SECTION M OPTIONS AND SPECIAL TOOLS INDEX.................................................................. 789 SECTION M4 ELECTRIC DRIVE COOLING AIR FILTER SYSTEM INDEX.............................................. 791 SYSTEM ADJUSTMENT.................................................................................. 793 PUMP............................................................................................... 796 Removal............................................................................................ 796 Disassembly........................................................................................ 796 Inspection......................................................................................... 796 Assembly........................................................................................... 796 Installation....................................................................................... 796 BLOWER DRIVE MOTOR................................................................................. 799 Removal............................................................................................ 799 Disassembly........................................................................................ 799 Inspection Of Parts................................................................................ 800 Assembly........................................................................................... 801 Installation....................................................................................... 802 BLOWER BEARING REPAIR.............................................................................. 802 Removal........................................................................................ 802 Replacement.................................................................................... 802 Assembly....................................................................................... 803 AIR CLEANER........................................................................................ 803 Assembly....................................................................................... 803 Removal........................................................................................ 803 Assembly....................................................................................... 803 SECTION M7 HEATER OPTIONS INDEX........................................................................ 805 GENERAL INFORMATION................................................................................ 807 TROUBLESHOOTING.................................................................................... 807 HEATER ELEMENT..................................................................................... 807 Removal........................................................................................ 807 Installation................................................................................... 808 GENERAL............................................................................................ 809 Maintenance.................................................................................... 809 HEATING ELEMENT.................................................................................... 809 Removal........................................................................................ 809 Installation................................................................................... 810 THERMOSTAT......................................................................................... 810 Removal........................................................................................ 810 Installation................................................................................... 810 GENERAL INFORMATION................................................................................ 811 TROUBLESHOOTING.................................................................................... 811 HEATER ELEMENT..................................................................................... 811 Removal........................................................................................ 811 Installation................................................................................... 812 SECTION M8 SPECIAL TOOLS............................................................................... 813 NITROGEN CHARGING VALVE............................................................................ 813 ROLL-OUT ASSEMBLY.................................................................................. 813 EYE BOLT........................................................................................... 813 OFFSET WRENCH...................................................................................... 814 TORQUE ADAPTER..................................................................................... 814 HANDLE............................................................................................. 814 SEAL INSTALLER..................................................................................... 814 SLEEVE ALIGNMENT TOOLS............................................................................. 815 QUICK DISCONNECT COUPLING.......................................................................... 815 HARNESS............................................................................................ 815 SEAL INSTALLATION RING............................................................................. 815 BELT TENSION TESTER................................................................................ 816 BELT ALIGNMENT TOOL................................................................................ 816 SOCKETS AND ADAPTERS............................................................................... 816 DUST CAPS.......................................................................................... 816 HYDRAULIC SYSTEM FLUSHING TOOLS.................................................................... 817 PAYLOAD DATA MANAGER............................................................................... 817 HYDRAULIC SYSTEM VACUUM PUMP....................................................................... 817 MISCELLANEOUS SERVICE TOOLS........................................................................ 818 BRAKE PISTON TOOL.................................................................................. 819 HIGH VOLTAGE TOOLS................................................................................. 822 2000 VDC METER..................................................................................... 822 GROUNDING STICKS................................................................................... 822 BODY PAD SPACER TOOL............................................................................... 823 RADIATOR SHUTTERS.................................................................................. 827 OPERATION...................................................................................... 827 Hydraulic Circuit.......................................................................... 827 Electrical Circuit:........................................................................ 828 MAINTENANCE AND REPAIR......................................................................... 828 TROUBLESHOOTING................................................................................ 829 Hydraulic Troubleshooting.................................................................. 832 Electrical Troubleshooting................................................................. 834 SECTION M19 RADIATOR SHUTTERS INDEX.................................................................... 825 RADIATOR SHUTTERS.................................................................................. 827 SECTION N OPERATOR'S CAB INDEX............................................................................. 835 SECTION N2 TRUCK CAB INDEX............................................................................. 837 TRUCK CAB.......................................................................................... 839 TRUCK CAB...................................................................................... 839 Description................................................................................ 839 Removal.................................................................................... 840 Installation............................................................................... 842 CAB DOOR....................................................................................... 842 Removal.................................................................................... 842 Installation............................................................................... 843 Door Adjustment............................................................................ 843 Door Jam Bolt Adjustment................................................................... 843 Door Handle Plunger Adjustment............................................................. 845 Replace Door Glass......................................................................... 846 Replace Door Window Regulator.............................................................. 850 Replace Door Handle or Latch Assembly...................................................... 850 Door and Door Hinge Seal Replacement....................................................... 851 Door Opening Seal Removal.................................................................. 851 Installation............................................................................... 851 GLASS REPLACEMENT.............................................................................. 852 Adhesive-Bonded Windows.................................................................... 852 Recommended Tools/Supplies................................................................. 852 Replacement Procedure...................................................................... 852 Windshield and Rear Glass.................................................................. 853 Removal.................................................................................... 853 Installation............................................................................... 854 Removal and Installation of Operator Seat...................................................... 855 Inspection................................................................................. 855 Removal.................................................................................... 855 Installation............................................................................... 855 Removal and Installation of Passenger Seat..................................................... 856 Removal.................................................................................... 856 Installation............................................................................... 856 SECTION N3 CAB COMPONENTS INDEX........................................................................ 857 WINDSHIELD WIPERS.................................................................................. 859 WIPER MOTOR REPLACEMENT........................................................................ 859 Removal.................................................................................... 859 Installation............................................................................... 859 WIPER ARM REPLACEMENT.......................................................................... 859 Removal.................................................................................... 859 Installation............................................................................... 860 WIPER LINKAGE REPLACEMENT...................................................................... 860 Removal.................................................................................... 860 Installation............................................................................... 861 WINDSHIELD WASHER.............................................................................. 861 Operation.................................................................................. 861 Service.................................................................................... 861 SEAT BELT...................................................................................... 862 Removal.................................................................................... 862 Installation............................................................................... 862 SECTION N4 OPERATOR COMFORT INDEX...................................................................... 865 HEATER / AIR CONDITIONER........................................................................... 867 Fan Speed Control Knob......................................................................... 867 Temperature Control Knob....................................................................... 867 Air Flow Directional Knob...................................................................... 867 Heater/Air Conditioner Vents................................................................... 868 COMPONENTS......................................................................................... 868 Fuse and Circuit Breaker....................................................................... 868 Relays......................................................................................... 868 Heater Core.................................................................................... 868 Fan Motor And Speed Control.................................................................... 869 Actuators...................................................................................... 869 Cab Air Filter................................................................................. 869 ENVIRONMENTAL IMPACT OF AIR CONDITIONING........................................................... 872 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.......................................................... 872 PRINCIPLES OF REFRIGERATION........................................................................ 872 Air Conditioning............................................................................... 872 Refrigeration - The Act Of Cooling............................................................. 873 The Refrigeration Cycle........................................................................ 873 AIR CONDITIONER SYSTEM COMPONENTS.................................................................. 874 Compressor (Refrigerant Pump).................................................................. 874 Service Valves................................................................................. 874 Condenser...................................................................................... 874 Receiver-Drier................................................................................. 874 Expansion Block Valve.......................................................................... 875 Accumulator.................................................................................... 875 Evaporator..................................................................................... 875 ELECTRICAL CIRCUIT................................................................................. 876 Thermostat..................................................................................... 876 Compressor Clutch.............................................................................. 876 Trinary™ Switch................................................................................ 877 SYSTEM SERVICING................................................................................... 878 SERVICE TOOLS AND EQUIPMENT........................................................................ 879 Recovery/Recycle Station....................................................................... 879 Leak Detector.................................................................................. 879 Service Valves................................................................................. 880 Vacuum Pump.................................................................................... 880 Manifold Gauge Set............................................................................. 881 Installing Manifold Gauge Set.................................................................. 882 Purging Air From Service Hoses................................................................. 882 SYSTEM PERFORMANCE TEST............................................................................ 883 SYSTEM OIL......................................................................................... 884 Handling and Reusing PAG Oil................................................................... 884 Oil Quantity................................................................................... 884 Checking System Oil............................................................................ 884 REFRIGERANT........................................................................................ 885 Recycled Refrigerant........................................................................... 885 Reclaimed Refrigerant.......................................................................... 885 Refrigerant Quantity........................................................................... 885 R-134a Refrigerant Containers.................................................................. 886 SYSTEM LEAK TESTING................................................................................ 886 Electronic Leak Detector....................................................................... 887 Tracer Dyes.................................................................................... 887 Soap and Water................................................................................. 887 RECOVERING AND RECYCLING THE REFRIGERANT........................................................... 887 Draining Oil from the Previous Recovery Cycle.................................................. 887 Performing the Recovery Cycle.................................................................. 887 Performing the Recycling Procedure............................................................. 888 Evacuating and Charging the A/C System......................................................... 888 SYSTEM REPAIR...................................................................................... 888 System Flushing................................................................................ 888 A/C DRIVE BELT CHECKOUT PROCEDURE.................................................................. 889 Pulley Alignment............................................................................... 889 Belt Tension Check............................................................................. 889 COMPONENT REPLACEMENT.............................................................................. 891 Hoses and Fittings............................................................................. 891 Lines.......................................................................................... 891 Expansion Valve................................................................................ 891 Receiver-Drier................................................................................. 891 Thermostat..................................................................................... 891 Compressor..................................................................................... 892 Accumulator.................................................................................... 892 Clutch......................................................................................... 892 Servicing the Compressor Clutch................................................................ 893 Pulley Removal................................................................................. 895 Clutch Coil Check.............................................................................. 896 Pulley Installation............................................................................ 896 Clutch Assembly Installation................................................................... 896 EVACUATING THE SYSTEM.............................................................................. 898 CHARGING THE A/C SYSTEM............................................................................ 900 Preliminary Checks............................................................................. 901 Diagnosis Of Gauge Readings And System Performance............................................. 901 SECTION N5 OPERATOR CONTROLS AND EQUIPMENT INDEX....................................................... 909 OPERATOR CAB AND CONTROLS.......................................................................... 911 STEERING WHEEL AND CONTROLS.................................................................... 912 STEERING WHEEL............................................................................. 912 HORN BUTTON................................................................................ 912 TILT/TELESCOPE LEVER....................................................................... 912 M ULTI-FUNCTION TURN SIGNAL SWITCH......................................................... 912 Turn Signal Operation.................................................................. 912 High Beam Headlight Operation.......................................................... 912 Windshield Wiper Operation............................................................. 912 STEERING COLUMN............................................................................ 913 Removal................................................................................ 913 Inspection............................................................................. 913 Installation........................................................................... 914 PEDALS......................................................................................... 914 SERVICE BRAKE PEDAL........................................................................ 914 DYNAMIC RETARDER PEDAL..................................................................... 914 Optional - Dual Function/Single Pedal.................................................. 915 THROTTLE PEDAL............................................................................. 915 GRADE/SPEED WARNING CHART.................................................................. 915 OVERHEAD PANEL CONTROLS AND COMPONENTS......................................................... 916 RADIO SPEAKERS............................................................................. 916 WARNING ALARM BUZZER....................................................................... 916 CAB RADIO.................................................................................. 916 WARNING LIGHTS DIMMER CONTROL.............................................................. 916 WARNING/STATUS INDICATOR LIGHT PANEL....................................................... 916 AIR CLEANER VACUUM GAUGES.................................................................. 916 WINDSHIELD WIPERS.......................................................................... 916 TRUCK CONTROLS............................................................................. 917 F-N-R Selector Switch.................................................................. 917 Hoist Control Lever.................................................................... 918 CONSOLE SWITCHES AND CONTROLS.............................................................. 918 Ashtray................................................................................ 918 Cigarette Lighter...................................................................... 918 Left-Hand Window Control Switch........................................................ 918 Right-Hand Window Control Switch....................................................... 918 Engine Shutdown Switch................................................................. 918 Override Switch........................................................................ 918 Retard Speed Control (RSC) Switch...................................................... 919 Retard Speed Control (RSC) Dial........................................................ 919 Statex III Download Port............................................................... 920 Engine Diagnostic Port (CENSE)......................................................... 920 Modular Mining Port.................................................................... 920 Passenger Seat......................................................................... 920 Engine Diagnostic Connectors........................................................... 920 Engine Diagnostics Connector........................................................... 920 Data Store Button...................................................................... 920 PAYLOAD METER.............................................................................. 920 Payload Meter Download Connector....................................................... 920 OPERATOR SEAT.................................................................................. 921 Seat Belts................................................................................. 921 ADJUSTMENT................................................................................. 921 INSTRUMENT PANEL............................................................................... 922 CONTROL SYMBOLS............................................................................ 922 CONTROL SWITCHES AND GAUGES................................................................ 923 Key Switch............................................................................. 923 Engine Shutdown Switch With Timer Delay................................................ 924 Fog Light Switch....................................................................... 924 Ladder Light Switch.................................................................... 924 Backup Light Switch.................................................................... 924 Panel Illumination Lights.............................................................. 924 Cab Air Conditioner/Heater Vents....................................................... 924 Engine Cold Weather Starting Aid Switch................................................ 924 Rotating Beacon Light Switch........................................................... 924 Heated Mirror Switch................................................................... 924 Wheel Brake Lock Switch................................................................ 925 Parking Brake Switch................................................................... 925 Digital Tachometer..................................................................... 925 Right Turn Signal Indicator Light...................................................... 926 High Beam Headlight Indicator Light.................................................... 926 Left Turn Signal Indicator Light....................................................... 926 Digital Speedometer/Payload Meter Display.............................................. 926 Voltmeter Gauge........................................................................ 926 Engine Oil Pressure Gauge.............................................................. 926 Engine Water Temperature Gauge......................................................... 926 Fuel Gauge............................................................................. 926 Engine Hourmeter....................................................................... 926 Headlight Switch....................................................................... 927 Panel Illumination Lights Dimmer Rheostat.............................................. 927 Payload Meter Switch................................................................... 927 OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL.................................................. 928 DESCRIPTION OF INDICATOR SYMBOLS........................................................... 929 INDICATOR LIGHT FUNCTIONS.................................................................. 930 A1. High Hydraulic Oil Temperature..................................................... 930 B1. Low Steering Pressure.............................................................. 930 C1. Low Accumulator Precharge Pressure................................................. 931 D1. Electric System Fault.............................................................. 931 E1. Low Brake Pressure................................................................. 931 A2. Low Hydraulic Tank Level........................................................... 931 B2. Automatic Lubrication System Pressure.............................................. 931 C2. Circuit Breaker Tripped............................................................ 931 D2. Hydraulic Oil Filter Monitor....................................................... 932 E2. Low Fuel........................................................................... 932 A3. Parking Brake...................................................................... 932 B3. Service Brake...................................................................... 932 C3. Body Up............................................................................ 932 D3. Dynamic Retarding.................................................................. 932 E3. Stop Engine........................................................................ 932 A4. Not Used........................................................................... 933 B4. Manual Backup Lights............................................................... 933 C4. Engine Shutdown Timer.............................................................. 933 D4. Retard Speed Control (RSC)......................................................... 933 E4. Check Engine....................................................................... 933 A5. Service Engine Indicator (AEM)..................................................... 933 B5. High Wheel Motor Temperature....................................................... 933 C5. Blower Fault....................................................................... 933 D5, E5, A6, B6, and C6. Not Used....................................................... 933 D6. Service Engine (CENSE)............................................................. 933 E6. Not Used........................................................................... 933 Komatsu Engines w/Centry™ Fuel Control................................................. 934 Hazard Warning Light Switch............................................................ 934 Lamp Test Switch/Centry™ Diagnostic Test Switch........................................ 934 TROLLEY INDICATOR LIGHTS................................................................... 934 A7. Diesel Power Indicator............................................................. 934 B7. Ready For Trolley Indicator........................................................ 934 C7. On Trolley Indicator............................................................... 934 D7. Trolley Fault Indicator............................................................ 935 E7. Left Limit Indicator (Optional).................................................... 935 A8. Max Speed Indicator................................................................ 935 B8. High Speed Indicator............................................................... 935 C8. Med Speed Indicator................................................................ 936 D8. Low Speed Indicator................................................................ 936 E8. Right Limit Indicator (Optional)................................................... 936 REAR AXLE LIGHT BAR........................................................................ 937 Backup Lights.......................................................................... 937 Retard Lights.......................................................................... 937 Brake Light............................................................................ 937 Backup Alarm........................................................................... 937 CENTRY™ FUEL SYSTEM DIAGNOSTICS................................................................ 938 GENERAL OPERATION.......................................................................... 938 DETERMINING FAULT CODES.................................................................... 938 EXITING THE DIAGNOSTICS MODE............................................................... 939 SECTION P LUBRICATION AND SERVICE INDEX.................................................................... 941 SECTION P2 LUBRICATION AND SERVICE INDEX............................................................... 943 GENERAL INFORMATION................................................................................ 945 HYDRAULIC TANK SERVICE............................................................................. 945 Adding Oil..................................................................................... 945 COOLANT LEVEL CHECK................................................................................ 946 Radiator Filling Procedure..................................................................... 946 Coolant Specifications......................................................................... 946 Unacceptable Practices......................................................................... 946 WHEEL MOTOR SERVICE................................................................................ 946 RESERVE ENGINE OIL SYSTEM (Optional)............................................................... 947 Reserve Oil Tank Filling Procedure (Remote fill)............................................... 947 Inline Screen.................................................................................. 947 QUICK FILL SERVICE CENTER.......................................................................... 948 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS........................................................ 950 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)............................................ 951 50 HOUR LUBRICATION AND MAINTENANCE CHECKS......................................................... 952 100 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................ 952 250 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................ 953 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)............................................ 954 500 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................................ 955 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)............................................ 956 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 957 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 958 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 958 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................... 959 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................................... 960 SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX.......................................................... 961 GENERAL DESCRIPTION................................................................................ 963 SYSTEM COMPONENTS.................................................................................. 964 Filter Assembly................................................................................ 964 Hydraulic Motor and Grease Pump................................................................ 964 Reservoir...................................................................................... 964 Fixed Pressure Reducing Valve.................................................................. 964 Flow Control Valve............................................................................. 964 Solenoid Valve................................................................................. 965 Vent Valve..................................................................................... 965 24VDC Lubrication Cycle Timer.................................................................. 965 Time Delay Module.............................................................................. 965 Pump Cutoff Pressure Switch.................................................................... 965 Unloader Valve................................................................................. 965 Pressure Switch................................................................................ 965 Manual Override Button......................................................................... 965 Injectors...................................................................................... 965 SYSTEM OPERATION................................................................................... 968 Normal Operation............................................................................... 968 Pressure Failure Detection Circuits............................................................ 969 GENERAL INSTRUCTIONS............................................................................... 970 LUBRICANT REQUIRED FOR SYSTEM.................................................................. 970 SYSTEM PRIMING................................................................................. 970 LUBRICANT PUMP................................................................................. 971 Pump Housing Oil Level..................................................................... 971 Pump Pressure Control...................................................................... 971 FILTER AND RESERVOIR........................................................................... 971 Filter Assembly Element.................................................................... 972 INJECTORS (SL-1 Series H)...................................................................... 972 Injector Specifications.................................................................... 972 Injector Adjustment........................................................................ 972 INJECTOR OPERATION............................................................................. 974 SYSTEM CHECKOUT................................................................................ 975 Lubrication Cycle Timer Check.............................................................. 975 Lubrication Cycle Timer Adjustment......................................................... 976 PREVENTIVE MAINTENANCE INSPECTION.............................................................. 976 10 Hour Lubrication System Inspection...................................................... 976 100 Hour Inspection........................................................................ 976 250 Hour Inspection........................................................................ 976 500 Hour Inspection........................................................................ 977 1000 Hour Inspection....................................................................... 977 PUMP REBUILD................................................................................... 978 Disassembly................................................................................ 978 Cleaning and Inspection.................................................................... 978 Assembly................................................................................... 980 VENT VALVE REBUILD............................................................................. 981 Disassembly and Assembly................................................................... 981 SYSTEM TROUBLESHOOTING CHART................................................................... 982 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 987 AXLE BOX....................................................................................... 987 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 988 ARMATURE AREA.................................................................................. 988 AT TIRE CHANGE................................................................................. 988 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 989 GENERATOR/ALTERNATOR........................................................................... 989 GRID BLOWER MOTOR.............................................................................. 989 CONTROL EQUIPMENT CHECKS....................................................................... 989 MOTORIZED WHEEL MAINTENANCE SCHEDULE............................................................... 990 VEHICLE OPERATIONS TESTS....................................................................... 990 SECTION P4 MOTORIZED WHEEL MAINTENANCE SCHEDULE INDEX.................................................. 985 SECTION R SYSTEM SCHEMATICS INDEX ......................................................................... 991 EF5755 BRAKE SCHEMATIC ................................................................................ 993 EM1369 HYDRAULIC SCHEMATIC............................................................................. 994 XS1000 ELECTRICAL SCHEMATIC............................................................................ 995 HE484 HVAC ELECTRICAL SCHEMATIC........................................................................1029
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
1 review for KOMATSU 730E TROLLEY DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30600 -A30616) KOMATSU 730E – PDF DOWNLOAD
Add a review
Ibrahim Ahmad –